Engineering Excellence: A Case Study of Precision in Refrigerated Storage Tank Fabrication

Precision engineering is the cornerstone of safety, efficiency, and reliability in energy infrastructure. This is especially true for projects that involve the fabrication and commissioning of refrigerated storage tanks, where every detail matters to ensure the secure containment of volatile substances. A recent project that Sharp Tanks and Structurals Pvt. Ltd. (STSPL) executed for SHV Energy Pvt Ltd exemplifies this ethos.

In the heart of Tuticorin, Tamil Nadu, SHV Energy Pvt Ltd, sought to bolster its infrastructure with two refrigerated storage tanks, each with a capacity of 15,000 metric tons. These tanks, designed to store propane and butane, were required to meet the stringent guidelines set forth by BVIS 2022. STSPL was given the responsibility to design, conceptualize, and commission the project.

The project’s intricacies were apparent from the outset. With dimensions stretching over 46.8 meters in diameter and 20 meters in height for the Outer Tank, and 45.2 meters in diameter and 18.4 meters in height for the Inner Tank, precision was non-negotiable. The storage of volatile substances demanded utmost caution, amplifying the need for error-free execution at every project lifecycle stage.

Navigating through phases of design, procurement, fabrication, and commissioning posed a multifaceted challenge. Each step demanded meticulous attention to detail, coupled with adherence to BVIS 2022 standards to ensure compliance and optimal operational efficiency and safety.

STSPL rose to the occasion to meet stringent quality control measures, third-party inspections, and the expertise of seasoned professionals across all project facets. The result was a resounding success; despite the project’s complexities, both refrigerated storage tanks were delivered on schedule, meeting and exceeding BVIS 2022 standards.

The significance of this achievement reverberated beyond mere project completion. It underscored STSPL’s unwavering commitment to excellence and safety, further solidifying its reputation as a trusted partner in the Oil & Gas sector. SHV Energy Pvt Ltd’s satisfaction served as a testament to the professionalism and dedication exhibited by STSPL throughout the project lifecycle.

The successful fabrication and commissioning of two refrigerated storage tanks underscored STSPL’s technical prowess and reinforced its position as a preferred partner for clients seeking uncompromising quality and reliability. The SHV Energy Pvt Ltd project is a testament to the transformative power of precision engineering and unwavering commitment to quality. 

15,000 MT Full Integrity Double Walled Storage Tanks Project Completed

A leading Indian energy organization entrusted Sharp Tanks and Structurals P. Ltd., a ZETWERK company, with a comprehensive project at Krishnapattanam Port, Andhra Pradesh. The assignment involved the design, engineering, procurement, supply, fabrication, inspection, transportation, storage, construction, installation, insulation design, and application, as well as testing, pre-commissioning, and commissioning of two state-of-the-art Full Integrity Double Walled Storage Tanks, each with an impressive capacity of 15,000 MT.

Challenge

The tanks, intended for the storage of propane and butane, featured outer tank dimensions of 46 meters in diameter and 21.59 meters in height, while the inner tank measured 44 meters in diameter and 20 meters in height. The design requirements, engineering specifications, and the complexity of managing the project from procurement to commissioning demanded high technical proficiency. Additionally, we had to ensure the integrity of the double-walled storage tanks, meet safety standards, and adhere to the regulations outlined by LRS 2022. The sheer scale of the storage tanks and the need for insulation design and application further underscored the challenges faced by the engineering team.

Impact

Successfully meeting and surpassing these challenges, we delivered two impeccably engineered and constructed Full Integrity Double Walled Storage Tanks to the client at Krishnapattanam Port. The impact of this achievement was substantial. It solidified Sharp Tanks’ reputation as a comprehensive solution provider for complex projects in the energy sector. The client benefited from enhanced storage capabilities, operational efficiency, and reliability

Advantage

The successful execution of this project further established Sharp Tanks and Structurals P. Ltd. as a preferred partner for companies seeking expertise in the design, fabrication, and installation of large-scale storage tanks. The ability to seamlessly handle every aspect of the project, from conception to commissioning, showcased our versatility and proficiency in the energy infrastructure domain.

Completing the Full Integrity Double Walled Storage Tanks project at Krishnapattanam Port marks another milestone in our commitment to delivering comprehensive and high-quality solutions for the energy sector

Vijaya Peri

Business Head – Oil & Gas

Pioneering Steel Girder Fabrication for India’s First Bullet Train: Zetwerk & L&T’s Triumph

Overview

The Mumbai-Ahmedabad Bullet Train, India’s first high-speed rail project, required a robust infrastructure capable of withstanding extreme loads and precise engineering specifications. One of the most critical components was the fabrication of 21-meter-high steel girders, which had never been successfully manufactured in India before. L&T, a leader in infrastructure development, partnered with Zetwerk to take on this ambitious challenge.

Zetwerk fabricated girders for L&T’s construction of the Mumbai-Ahmedabad Bullet Train rail corridor. These girders, including a record-breaking 130-meter long, 3000-MT girder, are crucial for supporting the load-bearing capacity of the steel bridges.

The Challenge

Initially, the fabrication of these specialized steel girders posed a significant hurdle. Given the lack of local expertise in India, previous projects had relied on imports from Japan. The project demanded strict adherence to Japanese manufacturing standards, necessitating advanced technical knowledge and precision engineering. Zetwerk recognized this challenge as an opportunity to revolutionize steel fabrication in India.

Innovative Solution & Execution

To bridge the knowledge gap, Zetwerk strategically engaged Japanese experts at its fabrication plant,
ensuring complete compliance with international standards. This collaboration allowed for the seamless
transfer of expertise, enabling Zetwerk’s skilled workforce to fabricate and erect these complex steel
structures with unparalleled accuracy.

Over a short span of 90 days, Zetwerk successfully fabricated 10,000 metric tons of steel girders for the Mumbai-Ahmedabad High-Speed Rail (MAHSR) project, with a contract value of approximately Rs. 150 crore. This accomplishment not only proved India’s capability to execute such projects domestically but also set a new benchmark in large-scale industrial fabrication.

Impact & Industry Advancemen

Zetwerk’s successful execution of this project demonstrated its ability to:

  • Meet the most stringent global engineering and manufacturing standards.
  • Establish itself as a trusted partner for complex infrastructure projects.
  • Reduce India’s dependence on imports by building indigenous capabilities in high-precision steel fabrication.
  • Enhance the skills of its workforce through knowledge transfer, ensuring long-term industry benefits.

A New Standard in Infrastructure Development

By embracing collaboration and innovation, Zetwerk turned an engineering challenge into a transformative success. The integration of imported expertise not only ensured the immediate success of the project but also positioned Zetwerk as a leader in the infrastructure manufacturing sector, committed to operational excellence and continuous improvement.

Leadership Insights

“Zetwerk’s 21-meter steel girder triumph is a testament to collaborative excellence. We showcase prowess in fabricating high-performance structures, innovating through challenges, and pioneering a dual-benefit approach,” said a Zetwerk business leader

Through this landmark achievement, Zetwerk has proven that India can lead in high-precision steel
fabrication, paving the way for future infrastructure innovations on a global scale.

For queries, please contact: marketing@zetwerk.com